MAKING MODERN LIVING POSSIBLE

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Technical Information

ACW112A,D
Level Controller
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powersolutions.danfoss.com
Technical Information
Ph ACW112A,D Level Controller

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2 BLN-95-8952-11 • 95-8952-11 • August 2004

Technical Information
Ph ACW112A,D Level Controller

PRODUCT OVERVIEW Description ....................................................................................................................................................... 4

Features ............................................................................................................................................................. 4
Ordering information................................................................................................................................ 4-5
Specify .......................................................................................................................................................... 4
Replacement parts ................................................................................................................................... 4
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Preferred Models....................................................................................................................................... 5
Part number quick reference..................................................................................................... 5
Dimensions....................................................................................................................................................... 6
Technical data.................................................................................................................................................. 7
Electrical data.................................................................................................................................. 7
Environmental data....................................................................................................................... 7
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Theory of operation....................................................................................................................................... 8
At level ............................................................................................................................................... 8
Off level ............................................................................................................................................. 8

PRODUCT INSTALLATION Installation and adjustments ...............................................................................................................9-10

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Installation................................................................................................................................................... 9
Mounting................................................................................................................................................ 9
Wiring ...................................................................................................................................................... 9
Connection diagram..................................................................................................................... 9
Adjustments .............................................................................................................................................10
Internal assembly with adjustment scale............................................................................10
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Technical Information
Ph ACW112A,D Level Controller

DESCRIPTION The ACW112 Level Controller measures deviation from a gravity reference for mobile
equipment such as hillside combines and aerial lifts. Its sensing and amplifying
components are contained within a single compact housing and are powered by either
a 12 or 24 V DC electrical system.
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The controller senses level through the interaction of a bearing-suspended magnetic
pendulum and Hall proximity sensors. Signals from the Hall sensors drive the amplifier,
which provides ON-OFF electric output to two solenoid valves. The switching signal
is instantaneous on the ACW112A and is delayed one quarter to one half second on
the ACW112D to allow it to disregard momentary slope deviations. Additionally, the
ACW112D has short circuit protection. Both have instantaneous turn-off.
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FEATURES • Capable of operation under severe dust and moisture conditions

• Solid state circuitry

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• Rugged aluminum housing

• Specially damped to resist response to normal machine oscillations

• Capable of driving solenoid valves directly, without additional signal amplification

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ORDERING See part number quick reference, page 5 for listing of preferred models. Consult Sauer-
INFORMATION Danfoss for other options.

Specify
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1. Model number ACW112A or D Level Controller. Two controllers must be ordered for
controlling two axes.

2. Voltage (12 or 24 V DC).

3. Setpoint desired.
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4. Time delay (when ordering the ACW112D).

Replacement parts
1. Refill kits containing the correct amount of silicone fluid (200 cc) for refilling one
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controller. Order with part number K05993 for 1000 CS oil K05997 for 5000 CS oil.

2. Replacement Hall effect switch. Order part number K05116.

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4 BLN-95-8952-11 • 95-8952-11 • August 2004

Technical Information
Ph ACW112A,D Level Controller

ORDERING Preferred models

INFORMATION
(continued) Part number quick reference
OS number Voltage (V DC) Time delay (seconds) Switch Points Oil viscosity (CS)
ACW112A1106 12 None 1.5° 5000
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ACW112A1122 12 None 0.5° 5000
ACW112A1130 12 None 1° 5000
ACW112A1163 24 None 5° 5000
ACW112A1171 24 None 1.5° 5000
ACW112A1189 24 None 1° 5000
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ACW112A1197 12 None 4.75° 5000
ACW112A1213 24 None 1° 4000
ACW112A1239 12 None 3° 5000
ACW112A1247 12 None 1.5° 1000
ACW112A1262 24 None 2° 5000
ACW112A1276 24 None 1.5° 1000
ACW112A1284 24 None 0.5° 5000
ACW112A1292 24 None 3° 5000
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ACW112D1004 12 0.5 1° 1000
ACW112D1012 12 0.5 1° 50
ACW112D1020 12 0.5 1.5° 1000
ACW112D1038 24 0.5 1.5° 1000
ACW112D1046 24 1.5 1.5° 3000
ACW112D1061 24 0.5 1° 1000
ACW112D1079 12 0.25 1° 5000
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ACW112D1087 12 0.25 1.5° 1000
ACW112D1095 24 0.5 5° 5000
ACW112D1111 24 0.25 1° 4000
ACW112D1129 12 1 1° 1000
ACW112D1137 24 0.75 1° 50
ACW112D1145 24 0.5 0.75° 1000
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ACW112D1152 12 0.5 0.5° 1000

ACW112D1160 24 0.5 7° 5000
ACW112D1177 24 1 1° 300
ACW112D1186 12 0.5 3° 5000
ACW112D1194 24 0.5 1° 5000
ACW112D1202 12 0.5 5° 5000
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ACW112D1226 12 205 7° 5000

ACW112D1234 12 1 4.7° 1000
ACW112D1242 12 0.5 1.5° 1000
ACW112D1250 12 0.5 4° 1000
ACW112D1268 12 205 7° 5000
ACW112D1282 12 0.5 5° 1000
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ACW112D1296 12 0.5 7° 1000

ACW112D1304 24 0.25 1° 1000
ACW112D1312 12 0.5 1° 5000
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Technical Information
Ph ACW112A,D Level Controller

DIMENSIONS Approximate mounting dimensions of the ACW112 in millimeters [inches].

95,2 [3.75]
47,6 [1.88] 68,3 [2.69]
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Clearance holes
9,52 [0.38] for 1/4 inch bolts
(3)
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138 [5.44]

Gauge points
119 [4.69] for leveling
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4 leadwires
9,52 [0.38] 76,2 [3.0] 610 [24.0]
301A
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Technical Information
Ph ACW112A,D Level Controller

TECHNICAL DATA Electrical data

Input voltage
11 to 15 V DC for 12 V models 22 to 30 V DC for 24 V models
Voltage drop
2.3 V DC (A models) 2.5 V DC (D models)
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Load current
4 A maximum
Time delay
1⁄4 and 1⁄2 second turn on delays typical on ACW112D. See part number quick reference, page 5.
Average short circuit current (ACW112D only)
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0.7 A maximum with 0.5 ohm maximum from output to ground
Standard setpoints
Fixed ±1°, ±11⁄2°, and ±43⁄4° models available. Consult Sauer-Danfoss for other options.
Differential
Typically less than 1⁄2°, turn on to turn off.
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Environmental data
Vibration
Withstands a vibration test designed for mobile equipment controls that includes two parts:
1. Cycling from 2 to 2000 Hz over a range of ±1.5 to ±3.0 Gs for a period of one hour (if there are four
resonant points), for two hours (if there are two or three resonant points) and for three hours (if there is
one or no resonant point). Cycling test performed on each of the three major axes.
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2. Resonance dwell for one million cycles over a range of ±1.5 to ±3.0 Gs for each of the four most severe
resonant points on each of the three major axes.
Shock
50 Gs for 11 milliseconds.
Three shocks in both directions of the three major axes, totaling 18.
Operating temperature
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-18 to +60° C (0 to 140° F).

The ACW112 will operate from -40 to +66° C (-40 to +150° F) with more liberal specifications.
Storage temperature
-40 to +77° C (--40 to +170° F)
Weight
3 lb 1 oz (1.4 kg)
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Technical Information
Ph ACW112A,D Level Controller

THEORY OF OPERATION The ACW112 houses a pendulum At level

suspended from two ball bearings on
a horizontal fixed shaft. The pendulum
acts as the system’s gravity reference
for vertical. Four permanent magnets Magnets Magnets
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assembled in an arc on the lower portion
of the pendulum activate two solid state N
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Hall effect switches.

Hall effect Hall effect
switch switch
Pendulum
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When leveled, both switches are OFF. Off level

When the unit is tilted to the right the
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pendulum rotates such that the right
switch is ON and the left switch is OFF. A
diode interlock circuit allows an external
manual switch to override the controller.
N N
S S
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Switch off Switch on

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When short circuit current reaches 5 amps in the D model, a current sensor turns the
power OFF. A short time delay follows until ON again and the cycle repeats. The internal
components are kept from burning because the ratio of time ON to time OFF is low.
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Technical Information
Ph ACW112A,D Level Controller

INSTALLATION AND Installation

ADJUSTMENTS Mounting
Before tightening down the mounting screws, the controller must be leveled. Ensure
that the machine is level. Use washers on the screws to make leveling easier. Place a
small bubble level against the gauge points on the right side edge of the base. Tighten
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the mounting screws firmly after the controller is level.

Wiring
A suggested wiring scheme is given utilizing a power switch, JOG switch and a fuse.
These are additional, optional components and are not supplied with the ACW112 Level
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Controller.

Connection diagram. Typical wiring to the ACW112.

ACW112 1 Rotation as viewed from cover side fo level controller

Black
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ON Emergency
OFF shut off switch

Red Fuse

5A
Yellow Powered on CCW error

1 Jog switch
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Orange Powered on CW error

1 Battery

284B
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CCaution
Be sure the black lead wire is grounded to the machine frame (minus side of the
electrical system). A poor ground connection will damage the controller.
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Technical Information
Ph ACW112A,D Level Controller

INSTALLATION AND Adjustments

ADJUSTMENTS The turn-on points of the Level Controller are factory set to order specification. Field
(continued) adjustment is not recommended. However, in new applications, it may be necessary
to change the setting for a particular type of machine. Should the turn-on points need
adjustment, use the following procedure.
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1. Turn power OFF and remove the ACW112 from the machine. Wipe off as much
dirt as possible, particularly from the gasket edge. The controller contains 200 CCS
damping fluid and care must be exercised when removing the cover to retain this
fluid. The fluid can be captured in the cover when the controller is taken apart by
positioning the controller with the cover down while removing the cover screws.
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Separate the base assembly from the cover and allow most of the oil to drain off.

2. Measure the distance from the edge Internal assembly with adjustment scale
of the right blade to its mounting
base and record the dimension.
Loosen the right blade locking
screw. To widen the turn on point,
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adjust the right blade outward. A
change in the right blade position to
its mounting base of .048 inch will
change the switch point a total of
1˚. Changes of less than 1⁄2˚ are not
recommended. 2

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3. Hold the blade in its new position
and tighten the blade locking screw.

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4. Hold the base assembly upright and rotate it side to side to be sure that the
pendulum swings freely. Some stickiness due to the oil will be observed when the
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pendulum touches the stop post.

5. Place the base assembly on the cover and install the cover screws. Mount the control
on the machine and check for proper operation.

It should be noted that this adjustment procedure is for the right blade; for small setting
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changes, the right blade only needs to be changed. Assume that the controller initially
was factory adjusted to give switch turn on points of ±11⁄2° setting with an additional
±1⁄2° added to this for a total of 2° switch turn on points. In the example just given, since
the right blade only was moved, it will be necessary to mount the controller 1⁄2° off the
vertical on the machine in order to maintain the same level position that was established
prior to the switch change.
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Technical Information
Ph ACW112A,D Level Controller

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Products we offer: Danfoss Power Solutions is a global manufacturer and supplier of high-quality hydraulic and
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Power Solutions US Company Power Solutions GmbH & Co. OHG Power Solutions ApS Power Solutions
2800 East 13th Street Krokamp 35 Nordborgvej 81 22F, Block C, Yishan Rd
Ames, IA 50010, USA D-24539 Neumünster, Germany DK-6430 Nordborg, Denmark Shanghai 200233, China
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already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed.
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10 BLN-95-8952-11 • 95-8952-11 • August 2004